Tree to outdoor furniture

[wtnhighlander]

I have the opportunity to build some outdoor-ready pieces from a cypress tree that I felled back in March.

I started breaking down the main log by hand, because I detest using the chain saw.

... But that was just silly. I finished slicing it down the middle, then left it to dry for the summer

No photos, but last weekend, Cody and I put some effort into stripping the bark. Enough water has left the wood that we could wrestle a log half into the shop for convenience.

There was a hump on this face from trying to split out the last section, as my saw bar was a bit short. I cross-cut it into sections...

Then knocked those sections out with a chisel.

I cleared about 16" in a 30-minute session this morning. This face should become the seat of the 'park bench', and I will only need to square the opposite face in areas that will join other parts.

[wtnhighlander]

So I finished chiseling away the hump this morning, and started working the twist out of the now flat-ish face. Tried the draw knife, but it is a bit to small to work that wide vace comfortably. Then I switched to my powered hand planer.

Hoping to limit the dispertion of chips to the area right below the log, I zip-tied a rag to the dust port, like a deflector. That sort of worked, at least the chips weren't flying EVERYWHERE. Then this happened...

I got it out, but ran out of time before getting all the housing screws back in.

[Ron Swanson Jr.]

On 9/11/2025 at 9:23 PM, wtnhighlander said:

So I finished chiseling away the hump this morning, and started working the twist out of the now flat-ish face. Tried the draw knife, but it is a bit to small to work that wide vace comfortably. Then I switched to my powered hand planer.

Hoping to limit the dispertion of chips to the area right below the log, I zip-tied a rag to the dust port, like a deflector. That sort of worked, at least the chips weren't flying EVERYWHERE. Then this happened...

I got it out, but ran out of time before getting all the housing screws back in.

The best laid plans of mice and men often go awry. Glad it worked out in the end!

[Von]

A good reminder about not wearing loose clothing!

[wtnhighlander]

Just a quick update to prove I haven't TOTALLY abandoned this ...

Progress on the flip side.

[wtnhighlander]

Had some time today, and got the seat slab pretty well flat. Now it's time to hack some stumpy little legs out of this other chunk of tree.

Roughly marked at the half-way point.

Clamp it down and started sawing...

Gonna take a while,but patience will eventually win.

[gee-dub]

That is gonna be great.  Looking forward to tagging along.

 

[Ron Swanson Jr.]

Go big or go home!! Looks good so far!

[Coop]

I don’t know how I missed this? You certainly have more gumption than I have with that hand saw! 
This is looking really cool! 

[Dave H]

Good for you @wtnhighlander I would have went for the chain saw....that's what us Neanderthal, wood butchers do. Your way is better of course!

[wtnhighlander]

@Dave H, trust me, if I had the opportunity to use my chainsaw, I'd be all over it! I am very restricted in when I can work on this, usually in early mornings, still dark outside, and trying not to wake the rest of the house. Plus, I enjoy the quiet, solitary hand tool work. But it sure would be nice to see the end of this project, somewhere on the horizon ....

[wtnhighlander]

Well, something has to give. My handsaw is good to about 3" of depth, then the wetter interior wood waste won't clear the cut, and jams. I even broke out my recip saw with a samauri sword on it to widen the kerf, but still stuck.

Oh, to have an electric chainsaw ...

Sorry about the dark photo. Flash was on, but I guess something mis-fired.

[Beechwood Chip]

On 10/22/2025 at 6:12 PM, wtnhighlander said:

I even broke out my recip saw with a samauri sword on it to widen the kerf, but still stuck.

Maybe shim up the log under the kerf, so the ends drop down and the kerf is pulled open?  If weight alone won't do it, maybe strap down the ends while propping up under the kerf.  And there's always pounding a wedge into the kerf above the blade.

[wtnhighlander]

Chip, this kerf is a loooong way from being wedged open. There is still a good 10" of wood to cut through. It is just so wet, and so much longer than my saw, the waste won't clear out.

[Beechwood Chip]

I think you're using the wrong saw 

 

[wtnhighlander]

I actually considered that, but at $250 average cost, I'd rather spend  $75 on a corded electruc chainsaw!

[Dave H]

I bought a corded chainsaw a few years back they come in handy from time to time...I keep it in the shop and, not in the tool shed with my other chainsaws. And they are quiet for when everyone else are still sleeping.

[wtnhighlander]

Should be smooth sailing, next chance I have to work!

Now, a question for the community: Anyone have tips for sizing the mortise and wedges for foxed tenons? I'm debating this idea for joining the seat slab to the legs without glue, fasteners, or visible joinery. I want this to look like just a slab resting across a couple of stumps. I'll add glue if necesary, but it will need to live with 100% weather exposure.

[Coop]

I made one similar several years back and used a single 2” pipe as a leg in the center. I welded a 1/2” steel plate to the pipe and cut a mortise in the bottom of the log seat and screwed the plate to the underside of the seat. Perhaps you could do the same with short 2’s screwed to the top of your legs and they could fit flush to the bottom of your seat in mortises? 

[Mark J]

13 hours ago, wtnhighlander said:

foxed tenons? I'm debating this idea for joining the seat slab to the legs without glue, fasteners, or visible joinery.

Is the wood fully dry?  

[wtnhighlander]

@Mark J, not by any stretch of the imagination!  

Wet wood was the driving factor in my purchase of the electric chain saw. 

[Mark J]

Then do you think the tenon might shrink and loosen, even if foxed?

[wtnhighlander]

"wiggly", yes. I'm hoping to avoid it just pulling out, though.

[Coop]

I’ve never heard of a fox wedged mortise and tenon until now. Just watched a video and that’s a neat deal! 

[Tom King]

I have a Craftsman tailed chainsaw that was new in 1975 that I still use occasionally.  I run the chain dry so it doesn't throw oil in old houses and it's surpring how long it lasts.  Fortunately it uses the cheap combo bar and chain sold for Poulan saws.

For that seat I would use tenons but cross toenail them with structural screws.  No one will turn it over to see how it was built.